lock MAZDA PROTEGE 1992 Repair Manual

ON-VEHICLE MAINTENANCE 62
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 DO11 102
Lock tool,
crankshaft
49 E011 103
Shaft
(Part of
49 EOl 1 1AO) @
49 EOI 1 104
Collar
(Part of
49 EOl 1 1AO) For
removal and
installation of
timing belt pulley
For
prevention of
engine rotation
For
prevention of
engine rotation 49 EOll IA0
Ring gear brake
set
49 EOll 105
Stopper
0
(Part of
49 EOI 1
1AO) w
49 SE01 310A
Centering tool,
clutch disc For
prevention of
engine rotation
For
prevention of
engine rotation
For
installation of
clutch disc
2311082-0‘
02-I 1

B2 ON-VEHICLE MAINTENANCE
TIMING BELT
Removal / Installation
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
/ 7.8-11 N.m
(80-l 10 Cm-kg, 69-95 in-lb
1p1\ ’ (3.8-6.3, 2738)
, (80-l 10 cm-kg, 69-95 in-lb)
167--187 (X-17, 116-123)
/ 7.8--11 N-m
(80-110 MI-kg,
7.8-11 N-m
\-
(80-110 Cm-kg, 69-95 in-lb)

12-17 (1.25-1.75, 9-13)
N-m (m-kg, &lb
23UOl32-0
1. Under cover and side cover 11. Timing belt cover, lower
2. P/S and/or A/C drive belt 12. Pulley lock bolt
3. Alternator drive belt Removal Note . . ..*..........*.*......... page 82-13
4. Water pump pulley Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
5. Plate 13. Pulley boss
6. Crankshaft pully 14. Timing belt
7. Spark plugs Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 62-13
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 62-15 Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-14
8. Oil dip stick 15. Tensioner and tensioner spring ..l
9. Timing belt cover, upper Installation Note ..,..................... page B2-14
10. Timing belt cover, middle 16. Idler
B2-12

ON-VEHICLE MAINTENANCE B2
13EOBZ00
13EOB2-009
13EOB2.Ol (
13EOB2-01;
Removal Note
Pulley lock bolt
1. Hold the pulley boss with the SST.
2. Using the SST, loosen the pulley lock bolt.
3. Remove the bolt and the pulley boss.
Timing belt
1. Install the pulley boss and pulley lock bolt.
2. Turn the crankshaft to align the timing marks.
Note
l The pin on the pulley boss must face upward.
Cautlon
l After setting the marks, do not turn the crankshaft
when removing the pulley lock bolt and pulley boss.
Note
l Mark the timing belt rotation for proper reinstal-
lation.
Caution
l Protect the tensioner with a rag before prying on it.
3. Loosen the tensioner lock bolt and, using a suitable bar,
pry the tensioner outward (arrow).
4. Tighten the lock bolt with the tensioner spring fully extended.
5. Remove the timing belt.
B2-13

B2 ON-VEHICLE MAINTENANCE
13EOB2-031
OWOBX-02
0311082.023
13EOB2-013
82-l 4
13EOB2-01
Installation Note
Tensioner and tensioner spring
1. Install the tensioner and the tensioner spring.
Caution
l Protect the tensioner with a rag before prying on it.
2. Using a suitable bar, pry the tensioner outward (arrow).
3. Temporarily tighten the tensioner lock bolt with the tensioner
spring fully extended.
Timing belt
1. Verify that the timing belt pulley mark is aligned with the tim-
ing mark.
2. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
3. Install the timing belt so that there is no looseness at the
idler side or between the camshaft pulleys.
4. Install the pulley boss and pulley lock bolt.
Caution
. Do not turn the crankshaft counterclockwise.
5. Turn the crankshaft two turns clockwise and face the pin
on the pulley boss upright.
6. Verify that the camshaft pulley marks are again aligned with
the seal plate marks.
If not aligned, remove the timing belt and repeat from ten-
sioner installation.
7. Turn the crankshaft 1 and 5/6 turns clockwise and align the
timing belt pulley mark with the tension set mark for proper
timing belt tension adjustment.
8. Using the
SST (49 DO1 1 102), loosen the pulley lock bolt
and remove the bolt and pulley boss.
Caution
l Do not turn the crankshaft. . .
9. Verify that the timing belt pulley mark is aligned with the ten-
sion set mark.

ON-VEHICLE MAINTENANCE
13EOB2-015
DEFLECTION CHECKING POINT
13EOE2-011
23UOB2-017
23UOB2-018
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page B2-8.) 10. Loosen the tensioner lock bolt to apply spring tension to
the timing belt.
11. Tighten the tensioner lock bolt.
Tightening torque:
37-52 Narn (3.8-5.3 m-kg, 27-38 ft-lb)
12. Install the pulley boss and pulley lock bolt.
13. Turn the crankshaft 2 and 116 turns clockwise and verify
that the timing marks are correctly aligned.
14. Measure the timing belt deflection by applying moderate
pressure (98 N,
10 kg, 22 lb) midway between the cam-
shaft pulleys.
If the deflection is not correct, repeat from Step 10 above.
Deflection:
9.0-11.5mm (0.35-0.45 In) at 98 N (10 kg, 22 lb)
Spark plug
1. Install the spark plugs.
Tightening torque:
15-23 Nern (1.5-2.3 m-kg, 11-17 ft-lb)
Pulley lock bolt
1, Hold the crankshaft with the SST and tighten the pulley lock
bolt.
Tightening torque:
157-187 N*rn (18-17 m-kg, 118-123 ft-lb)
23UOB2-019
82-l 5

ON-VEHICLE MAINTENANCE B2
- 05UOBX-04:
---_____~
OWOBX 04
----
05UOBX-03
4
2. Loosen the tensioner lock bolt.
Caution
l To prevent damage to the tensioner, secure it with
a rag.
3. Temporarily secure the tensioner with the spring fully ex-
tended.
Caution
Q Do not allow any oil or grease on the timing belt.
4. Remove the timing belt and secure it out of the way to pre-
vent damage during removal and installation of the cylin-
der head.
Cylinder head bolt
1. Loosen the cylinder head bolts in two or three steps in the
order shown in the figure.
2. Remove the cylinder head bolts.
Installation note
Cylinder head bolt
1. Apply clean engine oil to the bolt threads and seat faces.
2. Install the cylinder head bolts.
3. Tighten the cylinder head bolts in two or three steps in the
order shown in the figure.
Tightening torque:
76-81 N-m (7.7-8.3 m-kg, 56-60 ft-lb)
Cylinder head cover
1, Apply silicone sealant to the shaded areas as shown in the
figure.
2. Install the cylinder head cover.
Tightening torque:
4.9-8.8 N-m (50-90 cm-kg, 43-78 in-lb)
B2-19

B2 ON-VEHICLE MAINTENANCE
03UOB2-033
FOUR TEETH
13UOB2-015
05UOBX-032
B2-20
Timing belt
1. Check that the ignition timing mark (yellow) on the crank-
shaft pulley and the timing mark on the timing belt cover
are aligned.
2. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
Caution
l For intake side, align the I mark.
l For exhaust side, align the E mark.
3. Install the timing belt so that there is no looseness at the
idler side or between the two camshaft pulleys.
Caution
l Do not turn the crankshaft counterclockwise.
4. Turn the crankshaft two turns clockwise, and align the tim-
ing belt pulley mark with the timing mark.
5. Verify that the camshaft pulley marks are aligned with the
seal plate marks.
If not aligned, remove the timing belt and repeat from ten-
sioner installation.
6. Turn the crankshaft 1 and 5/6 turns clockwise, and align
the fourth tooth from the
I mark with the seal plate mark.
7. Loosen the tensioner lock bolt to apply tension to the tim-
ing belt.
8. Tighten the tensioner lock bolt.
Tightening torque:
37-52 N#rn (3.8-5.3 m-kg, 27-38 ft-lb)
9. Turn the crankshaft 2 and l/6 turns clockwise and verify
that the timing marks are correctly aligned.

ON-VEHICLE MAINTENANCE 82
I 05UOBX-049
05UOBX-C
05UOBX-0
03UOB2-1
Removal note
Camshaft pulley
1, Hold the camshaft with a wrench at hexagonal portion.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley.
Camshaft
1. Loosen the camshaft cap bolts in two or three steps in the
order shown in the figure.
2. Remove the camshaft caps.
3. Remove the camshaft.
4. Remove the camshaft oil seal from the camshaft.
HLA
Caution
l Mark the HLA with a felt pen so that they can be rein-
stalled in the position from which they were
removed.
1. Remove the HLA from the cylinder head.
Installation note
HLA
1. Apply clean engine oil to the friction surfaces.
2. If the HLA are being reused, install them in the position from
which they were removed.
3. Verify that the HLA move smoothly in their bores.
Camshaft
Note
l The intake camshaft is grooved for the distributor
drive.
1. Apply clean engine oil to the camshaft journals and bearings.
2. Install the camshaft in position.
82-23

ON-VEHICLE MAINTENANCE B2
05UOBX-05
BLA-DE 0-dlNG
Steps After Installation
1. Connect the negative battery cable.
2. Start the engine and check as follows:
l Ignition timing. (Refer to page 82-8.) 3. Install the camshaft pulley lock bolts.
4. Hold the camshaft with a wrench.
5. Tighten the camshaft pulley lock bolt.
Tightening torque:
49-61 N-m (5.0-6.2 m-kg, 36-45 ft-lb)
Distributor
1. Apply grease to a new O-ring and the blade.
2. Install the distributor and loosely tighten the installation bolt.
3. Connect the distributor connector.
0311082-039
B2-25

B2 ON-VEHICLE MAINTENANCE
FRONT OIL SEAL
Replacement
1. Disconnect the negative battery cable.
2. Raise the vehicle on a lift and remove the right front wheel.
3. Remove in the order shown in the figure, referring to
Removal Note.
4. Install in the reverse order of removal, referring to Installation Note.
I

@Em
157-167 (16-17, 116-123)
N.m (m-kg, ft-lb
1. Timing belt related parts.. ............ page B2-12
2. Pulley lock bolt
Removal Note ..................................... below
Installation Note.. page B2-27 ......................
3. Pulley boss
4. Timing belt
Removal Note.. ......................... page B2-13
Installation Note ........................ page B2-14 5. Timing belt pulley
Installation Note..
...................... page B2-27
6. Oil seal
Removal Note.. ......................... page B2-27
Installation Note.. ...................... page B2-27
Removal Note
Pulley lock bolt
1. Hold the pulley boss with the SST.
2. Loosen and remove the pulley lock bolt.